Bag-in-box with collapsed head-space

ABSTRACT

The present invention is directed to a bag-in-box package having a flowable product contained in a thermoplastic bag which is inserted in or encased within an outer relatively rigid box or carton is provided. The box or carton may be constructed from a rigid or semi-rigid plastic or paperboard and has (i) a flat bottom panel, an opposing top panel, and a self-supporting, upstanding wall connecting the bottom and top panels, and (ii) an access port through the box for inserting a rigid implement, such as a drinking straw or other spout/tap therethrough to puncture the bag and withdraw the flowable product from inside the bag. The flowable product occupies less than 100% of the available volume of the bag and the remaining available head-space volume above the product is evacuated or collapsed in order to prevent spillage or leakage of product from the straw or spout when the bag is punctured.

BACKGROUND OF THE INVENTION

The present application relates generally to retail packaging suitablefor packaging medium to individual sized portions of liquid or flowableproducts such as juice, milk, syrup, wine, sauces, oils, soup, broth,sugar, salt, confectionary pieces, birdseed, food or non-food particles,pellets, or liquids, skin care products, jewelry beads, BB shot, etc.

Retail packaging for flowable solid and/or liquid products iscommercially available in many styles and sizes e.g. 6-8 ounce singleserve juice boxes, stand up pouches (SUPs) containing alcoholic ornon-alcoholic beverages, retort and aseptic boxes for a range of fooditems such as broths, soups, milk, fruit or vegetable juices or purees,etc. Both food and nonfood retail packages are available in a widevariety of sizes and shapes. For example, metal cans made from aluminum,steel and other materials are well known. Plastic and glass jars,bottles and tubs as well as plastic and paper bags including pouches,envelopes, stick packages, etc., are all ubiquitous in modern commerce.Suitable packaging, e.g. for flowable articles which comprise (i)liquids or (ii) a multitude of small solid products ranging from itemssuch as cinnamon candies to BB shot, should contain the product withinthe package while protecting the product from contamination anddeleterious effects from the external environment. Thus, containers mayprotect their contents from contact or exposure to unwanted materialssuch as dirt, dust, microbes, insects, air, moisture, sunlight, etc.Also, the materials used in constructing packaging and especially for aproduct such as a food (including drink or drug, the product contactinterior surface layer of the package should resist migration ofchemicals between the product and the package materials. Examples ofprior art packaging include U.S. Pat. Nos. 1,157,462; and 3,314,210.

As previously noted, disposable, single serve, drink boxes and beveragepouches are well-known in the art, see e.g. U.S. Pat. No. 3,380,646(Doyen). Typically, a drink box comprises a cardboard box, laminatedwith plastic, and lined with a metal foil or plastic liner that containsa beverage, typically a fruit flavored drink or non-carbonated juicesuch as apple, grape, or orange juice, see e.g. U.S. Pat. No. 4,590,126for an example of a laminate material that may be employed. The beverageproduct contained in a single serve drink box is typically consumedthrough a straw. Often a rigid plastic straw is provided with each boxfor insertion through a hole in the cardboard box, which provides anaccess point for piercing the liner with an end of the straw, see e.g.U.S. Pat. Nos. 4,660,737 and 4,778,053.

SUMMARY OF THE INVENTION

A retail bag-in-box package having a flowable product contained in athermoplastic bag which is inserted in or encased within an outerrelatively rigid box or carton is provided. The box or carton may beconstructed from a rigid or semi-rigid plastic or paperboard and has (i)a flat bottom panel, an opposing top panel, and a self-supporting,upstanding wall connecting the bottom and top panels, and (ii) an accessport through the box for inserting a rigid implement, such as a drinkingstraw or other spout/tap therethrough to puncture the bag and withdrawthe flowable product from inside the bag. The bag is a retail sized,flexible thermoplastic bag (capacity≤1 liter) attached to an interiorsurface of the box proximate the access port. In some preferredembodiments, the bag-in-box package of the present invention ishand-held, e.g., designed to be used while being held in one hand by theconsumer.

An important aspect of the present invention is that the flowableproduct occupies less than 100% of the available volume of the bag andthe remaining available head-space volume above the product is evacuatedor collapsed in order to prevent spillage or leakage of product from thestraw or spout when the bag is punctured. When a bag is pierced with astraw or other rigid implement, the consumer must manually hold the boxto insert the straw. Typically, the box and bag are squeezed together byones fingers creating a positive pressure within the bag. If the bag iscompletely filled with product or when there is a gas-filled head-spaceabove the product in a less than a completely filled bag, the pressureinside the bag causes liquid product to rapidly exit through the strawand spill out onto the consumer. With the present invention, it isimportant to not only limit the amount of product within a particularvolume of bag, but also provide a collapsed head-space above theproduct. It has been discovered that when the product occupies at mostabout 83% of the available volume of the bag and the remaining volume(“head-space”) above the product is collapsed and un-filled, spillageduring piercing can be minimized or eliminated. In preferredembodiments, the flowable product occupies at most about 87%, 83%, 75%,67% or 58% of the available volume of the bag and the remaininghead-space, volume above the product is void of any injected gas andproduct. In these embodiments, the flowable product occupies at leastabout 33%, 42%, or 50% of the available volume of the bag.

The inventive package is suitable for packaging small lowable articlesor products (including either solids and/or liquids) of a size typicalfor consumer or individual use. Examples of products which may bepackaged in accordance with the present invention include withoutlimitation: milk, fruit or vegetable juices or purees such as: apple,apricot, black currant, cherry, grape, peach, pear, pineapple, orpomegranate juice; citrus juices like orange, grapefruit, and lemonjuice, carrot juice; tomato juice or puree; non-alcoholic or alcoholicdrinks such, as water, flavored water, juice, tea, or wine; honey;syrups for sweetening foods e.g. pancake syrup; syrups for flavoringbeverages e.g. soft drinks including homemade lemonade, juice flavoreddrinks or foods or food ingredients or condiments such as broth, soup,vinegar, soy sauce, ketchup, prepared mustard, mayonnaise, sauces,seeds, nuts, mints, or gum pieces; oils such as olive oil, coconut oil,walnut oil, peanut oil, etc.; salad dressings; personal care productssuch as soap, lotion, humectants, conditioners, nail polish, nail polishremovers; and other small flowable items, such as household or gardenchemicals, liquids such as alcohol, mineral oil, motor oil, orlubricants.

According to the invention, a hermetically sealed bag containing aflowable product is loaded into a rigid or semi-rigid box withattachment means such as adhesive disposed proximate to an access portto seal the bag thereto. After closing the box so that it contains thebag, the consumer or retail sized bag-in-box may be shipped to retailoutlets and stored or displayed for sale on store shelves. A consumerwill access the flowable or liquid product held therein by inserting adispensing fitment, e.g., straw through the access port thereby piercingthe bag film which is held in place against the box adjacent to theaccess port e.g. by adhesive. This helps to ensure a non-leakingconnection. The straw or fitment may then be used to remove the contentsof the bag-in-box. Although in many embodiments the access port will belocated on the uppermost or top surface of the box or rigid container,it is contemplated that this port may be located on other surfacesincluding front, back, or side wall surfaces at any desired locationwhether proximate the top or not. In some embodiments in may beadvantageous to have a bottom access port to permit use of a gravityfeed dispenser e.g., for hand lotion, soap and the like.

For the package to function properly the bag and box need to interact.Thus, for a puncturing device to poke through the bag or poucheffectively, in one preferred embodiment, the bag ideally is attached toa top lid of the box or carton. This ensures the bag stays at the top ofthe carton and is not pushed down away from the top with the appliedforce. If the bag is not securely attached to the top lid of the box,the pressure created, e.g. from a straw, tends to force liquid contentsout which creates a mess. For pre-applied attachment a registeredprinted wax coating or wax coated plastic film may provide good adhesionof the bag to the box and advantageously melt attaches at a very lowtemperature. For liquids packaged by a hot fill process (or by use ofexternal heat in the downstream process) this heat may seal the bag tothe box once the lid of the box is closed. Wax or a very thin filmcoating could cover the die cut access port hole in the carton as longas it does not increase puncture resistance significantly. However, itis advantageous for the access port to be free of adhesive or to haveeasily removable covers to facilitate puncture opening of the bag toaccess the bag contents.

Another option for adhesion of bag to box is be to use hot glue or a PSAtype material to adhere the pouch to the carton. The best location forthe hot glue is around the perimeter of the access port hole (creating aring) without going into the area to be punctured. Glue in the area tobe punctured may undesirably increase the force needed to puncture thepouch. Alternative attachment means include glue patterns of e.g. two ormore dots or stripes of glue on either side of the hole. Patterns thatdo not work well include attaching the pouch to the carton far away fromthe punctured area (as in side flaps) or on only one side of the hole.This causes the bag to pull away from the box or deflects the path ofthe straw in straw plus drink box embodiments.

In the case of a fitment, the fitment may be applied to either the boxtop or to the face of the inner bag with a die cut or perforated area ofthe box for the fitment to slot into or be pulled through respectively.In order to dispense a liquid without the top lid popping off, a top lidon the box must either be attached to the bag or the interior wall ofthe box.

Puncturing devices such as straws, pumps, or sprayers, may use a sharpend to puncture the bag. In the case of a pump or sprayer device, thedevice would need to adhere to the outside of the box. This may beaccomplished by various means including e.g. the use of a liner on thetop of the box that would expose a PSA when removed.

Fitments may also be placed on the face of the bag and not in the sealedarea. The bag film may be die cut to form a hole and a fitment sealedover the hole or alternatively a suitable fitment that cuts into thefilm may be employed. Fitments may be placed in the seal area andprotrude from the top of the box. A fitment attached washer may be usedto connect to both bag and box with opposing sides of the washer beingsealed by fusion or adhesive to bag and box, respectively.

After use, the bag may conveniently be separated from the box and eachcomponent may enter a recycling stream or the materials chosen for thebag and box may be selected for single stream recycling. Advantageously,the box may collapse flat to take up less space.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present invention will becomeapparent from the following detailed description, taken in combinationwith the appended drawings, in which:

FIG. 1 is a schematic view of a portion of one embodiment of a flexiblethermoplastic web for use in the present invention.

FIG. 2 is a schematic view showing formation of a flexible bag from aflexible thermoplastic web in accordance with the present invention.

FIG. 3 is a perspective view of a bag made from a flexible thermoplasticweb in accordance with the present invention.

FIG. 4 is a top plan view illustrating a rigid or semi rigid box blankin accordance with the present invention.

FIG. 5 is a perspective view illustrating the box of FIG. 4 assembledinto a parallelepiped box in accordance with the present invention.

FIG. 6 is a top plan view of the box of FIG. 5 in accordance with thepresent invention.

FIG. 7 is a bottom plan view of the box of FIG. 5 in accordance with thepresent invention.

FIG. 8 is a perspective view of an embodiment of a fully assembledbag-in-box package illustrating the bag of FIG. 3 attached to a box inaccordance with the present invention.

FIG. 9 is a side view of the assembled bag-in-box of FIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

As used herein with respect to packaging films, sheets, or planarcontainer materials including plastic materials, the term “rigid” meansa material having a Gurley stiffness of at least 1000 milligrams (mg)force in each of its machine direction and transverse direction. Astandard test method for determining the rigidity, stiffness valuesdescribed herein is a Gurley Stiffness test, a description of which isset forth in TAPPI Standard Test T 543 and ASTM D 6125-97. A suitabletesting apparatus is a Gurley Digital Stiffness Tester: Model 4171DS1Nmanufactured by Teledyne Gurley (514 Fulton Street, Troy, N.Y.12181-0088). This instrument allows the testing of a wide variety ofmaterials through the use of various lengths and widths in combinationwith the use of a 5, 25, 50, or 200 gram weight placed in one of threepositions on the pointer of the apparatus.

Referring to the drawings, in all of the figures it will be appreciatedthat dimensions and relative sizes are not to scale but are chosen toillustrate the invention and its various aspects and features.

Referring now to the drawings, FIG. 1 is a schematic view of a portionof a flexible thermoplastic film web 10 having a plurality of layers 11,12, 13 14, 15, 16, 17, 18, 19, 20, 21, 22 and 23. Film web 10 has afirst exterior surface 24 and an opposing second exterior surface 25.The film web 10 is depicted with a plurality of layers which correspondto the layers indicated in Table 1.

TABLE 1 Layer % FIG. 1 Composition Layer Number Identifier ThicknessComposition 11 A 12.85 82.4% C₂C₈ LLDPE 10.0% C₂C₈ VLDPE 7.6% Additives12 B 7.55 80% C₂C₈ LLDPE 20% anhydride modified LLDPE 13 C 3.9 80.00%nylon 6 20.00% nylon 6/66 14 D 10.55 100% (wt.) EVOH (38 mol %) 15 E 3.980.00% nylon 6 20.00% nylon 6/66 16 F 5.6 80% C₂C₈ LLDPE 20% anhydridemodified LLDPE 17 G 11.2 100% (wt.) EVA (12% VA) 18 F 5.6 80% C₂C₈ LLDPE20% anhydride modified LLDPE 19 E 3.9 80.00% nylon 6 20.00% nylon 6/6620 D 10.55 100% (wt.) EVOH (38 mol %) 21 C 3.9 80.00% nylon 6 20.00%nylon 6/66 22 B 7.55 80% C₂C₈ LLDPE 20% anhydride modified LLDPE 23 A12.85 82.4% C₂C₈ LLDPE 10.0% C₂C₈ VLDPE 7.6% Additives

An example of a commercially available linear low-density polyethyleneC₂C₈ LLDPE suitable for use in the present invention includes, but isnot limited to, Dowlex® 2045G having a reported density of 0.920 g/cm³,a melt index of 1.0 dg/min., and a m.p. of about 122° C., which issupplied by The Dow Chemical Company of Midland, Mich., U.S.A.

Exemplary of commercially available VLDPEs suitable for use in thepresent invention include, but are not limited to, the C₂C₈ Attane®family of resins, e.g., Attane® NG 4701G having a reported density of0.912 gram/cm³, a melt flow index of 0.8 decigram/min., which issupplied by The Dow Chemical Company of Midland, Mich., U.S.A.

Exemplary of commercially available anhydride-modified linearlow-density polyethylenes (mod-LLDPE) suitable for use in the presentinvention include, but are not limited to, the BYNEL® family of resins,e.g., BYNEL® 41E710 grade having a reported melt index of 2.7 dg/min.(at 190° C.) a density of 0.91 g/cm³, and a melting point of 115° C.,which is supplied by E. I. du Pont de Nemours and Company, Wilmington,Del., U.S.A.

Exemplary of commercially available ethylene/vinyl alcohol copolymerssuitable for use in the present invention include, but are not limitedto, the SOARNOL® family of resins, e.g., SOARNOL® ET3803 grade having areported bulk density of 0.64-0.74 gram/cm³, a relative density of1.13-1.22 gram/cm³, a melting point of 164-188° C., which may beobtained from The Nippon Synthetic Chemical Industry Company, Ltd.(Nippon Gohsei), Osaka, Japan.

Exemplary of commercially available polyamides suitable for use in thepresent invention include, but are not limited to, the ULTRAMID® familyof resins, e.g., ULTRAMID® B36 nylon 6 having a glass transitiontemperature (T_(g)) of 127° C., a density of 1.13 g/cm³, and tensilestrength (at yield) of 131,000 psi, and C40 nylon 6/66 having a m.p.193° C., and a density of 1.12 g/cm³, both of which may be obtained fromBASF, Mount Olive, N.J., U.S.A.

An example of commercially available ethylene vinyl acetate copolymer(EVA) includes, but is not limited to, Elvax® 3135XZ EVA having areported vinyl acetate (VA) content of 12%, a density of 30 gram/cm³, amelt index of 0.35 gram/10 min., a melting point of 95° C., which issupplied by E. I. du Pont de Nemours and Company, Wilmington, Del.,U.S.A.

In this embodiment of the invention, a seven layer film tubular blownfilm is made and the bubble is collapsed with application of heat andpressure to form a thirteen layer film web 10 useful for making a bag inaccordance with the present invention. It will be appreciated that avariety of film compositions and structures may be employed in thepresent invention and the depicted film web 10 is exemplary only. Web 10has a first exterior surface 24 which is the product contact surface andmay be designed with desirable properties for contact with the productto be packaged, e.g. inertness, heat-sealability, etc., and since inthis collapsed bubble embodiment this surface is provided by layer 24which is the same composition as distal opposing layer 11 having thesame composition for second exterior surface 25, this layer 11 andsurface 25 may also have suitable properties of abrasion resistance,heat-sealability, etc. Other functional layers are presented asintermediate layers 12-22 and these properties may beneficially includegas barrier e.g. oxygen barrier properties such as may be provided byEVOH containing layers 14 and 20, and to a lesser extent nyloncontaining layers 13, 15, 19, and 21. Polyethylene containing layersincluding surface layers 11, and 23 as well as intermediate layers 12,16, 17, 18, and 22 all provide water barrier properties. Each layer isalso designed for good adherence to adjacent layers and layers 12, 16,18, and 22 contain special adhesive polymers blended therein to enhancedelamination resistance. The central core layer 17 has an EVA polymerwith self-wetting properties which promote bonding to itself in thebubble collapsing process. The entire film web structure cooperates toform a supple conformable film web 10 which will easily flex and bend tofit an interior shape of a rigid or semi-rigid box as shown e.g. inFIGS. 5-8. The film structure is designed to have good ability to bepierced by a rigid implement such as a hard plastic straw or otherfitment when it is attached to a box proximate an access port. Thepuncture resistance may be adjusted by changes to the film compositionwithout undue experimentation e.g. the nylon layer thicknesses may bedecreased to increase the ease of piercing. This particular structure isbelieved to seal well around the piercing site and fitment e.g. strawwall, to reduce the possibility of leakage.

Advantageously, in some preferred embodiments, the bags formed with web10 as described herein have a WVTR of less than 0.5 g/100 in²/24 hoursat 100° F. (38° C.), 90% Relative humidity (R.H.), and 1 atmosphere andless than 0.1 g/100 in²/24 hours at 100° F. (38° C.), 90% Relativehumidity (R.H.), and 1 atmosphere.

In some preferred embodiments, bags ay also have O₂TR value of less thanor equal to 10 cm³/100 in²/24 hours at 1 atmosphere, 23° C. and 0% RH.In some preferred embodiments, the bags formed with web 10 have anElmendorf tear strength value of at least 100 grams in at least one ofthe machine and transverse directions.

Advantageously, in some preferred embodiments, the bags formed with web10 as described herein have has a Gurley stiffness of less than 50grams.

In some preferred embodiments, the bag is a retail sized, flexiblethermoplastic bag, i.e., having an available internal volume capacity ofequal to or less than 1 liter.

Advantageously, in some preferred embodiments, the bags of the presentinvention will have a puncture resistance value of less than or equal to22.2 N (5 pound-force), less than 17.8 N (4 pound-force), less than 13.3N (3 pound-force) or less than 8.9 N (2 pound-force).

Referring now to FIG. 2, a schematic view shows formation of a pluralityof bags including a flexible bag 34 from film web 10, the bag film web10 is placed on a conventional vertical form-fill-seal machine which isequipped for aseptic packaging. Web 10 is folded with first exteriorsurface 24 becoming the interior surface of the bag 26. Formation of avertical lap seal 27 is depicted, although other seals such as a finseal may be made as is known in the art. Web 10 has a first side edge 28and opposing second side edge 29 which are made to overlap with edge 28overlapping edge 29 a sufficient distance to permit a vertical seal 27to be formed e.g. by application of heat and pressure, or by ultrasonicsealing means thereby forming a tube 30 which is transversely sealed byconventional means to form a first transverse seal 31. The transverselysealed tube 30 may be filled with a flowable product and a bag 26 formedby a second opposing transverse seal 32. It will be appreciated that thetransverse sealing operation may provide the second closing seal 32simultaneously with the first transverse seal 31 for a trailing secondbag 33 in a continuous process and that seals 31 and 32 may be formed asa single wide seal which is longitudinally severed as part of thatprocess to form individual bags filled with product, one of which isshown in FIG. 3.

Referring now to FIG. 3, a perspective view of a bag 26 made from aflexible film web 10 is shown. Bag 26 is formed from film web 10 byprovision of a longitudinal fin seal 5 and first and second opposingspaced apart transverse seals 36, 37. Bag 26 is only partially filledwith a product 38 such as a liquid juice beverage to create an un-filledcollapsed head-space 39 above the product. As previously mentioned, theproduct occupies at most about 83%, 75%, 67% or 58% of the availablevolume of the bag. The remaining volume of the bag, i.e., head-space 39should be void of product and any additional injected gas to allow thisportion of the bag to collapse upon itself.

Referring now to FIG. 4, a top plan view illustrating one preferredembodiment of a rigid or semi-rigid box blank 40, preferably of eitherpaperboard or any plastic material such as, but limited to amorphouspolyethylene terephthalate (APET) in accordance with the presentinvention. It should be appreciated that any rigid or semi-rigid plasticweb or laminate may also be utilized in constructing boxes of thepresent invention. In some preferred embodiments, the plastic web orlaminate is entirely transparent.

Box blank 40 has a die cut perimeter edge 41 with a plurality ofvertical fold lines 41, 42, 43, and 44 extending from box top 45 to boxbottom 46, and a plurality of horizontal fold lines 47, 48, and 49extending from a first box side edge 50 to an opposing spaced apartdistal second box edge 51. Box black 40 also includes a back wall panel52 is defined by vertical fold lines 41, 42 and horizontal fold lines 48and 49. These fold lines may also be score lines, i.e., fold/score linesformed in a plastic material in order to fold a rigid plastic box blankinto a container. The phrase “fold/score lines” should be understood torefer to folds and/or score lines formed in rigid or semi-rigidpaperboard or plastic box blanks.

The vertical and horizontal fold/score lines in rigid and semi-rigidplastic webs may be formed by mechanical and/or optical ablationtechniques well known in the art.

Integrally connected to the back wall panel 52 at fold/score line 48 istop panel 53 which is defined by fold/score line 48, top edge 54, firsttop panel side edge 55 and second top panel side edge 56. A portion ofthe top panel between the top edge 54 and fold/score line 47 forms a topfold tab 57 which is adapted to be folded about fold/score line 47 toclose the box after assembly and loading with a product filled bag asfurther described below. Top panel 53 is provided with an access portshown as hole 58. Also, integrally connected to the back wall panel 52at fold/score line 49 is first bottom panel 59 which is defined byfold/score line 49, back panel bottom edge 60, first back bottom panelside edge 61 and second back bottom panel side edge 62.

Integrally connected to the back wall panel 52 at vertical fold/scoreline 41 is a first side wall panel 63 which is defined by fold/scorelines 41, 48, and 49 and first box side edge 50. Integrally connected tothe first side wall panel 63 at fold/score line 48 is first side wallpanel top flap 64 having an inverted “U” shaped first side wall paneltop flap edge 65. Integrally connected to the first side wall panel 63at fold/score line 49 is first side wall panel bottom flap 66 having a“V” shaped first side wall panel bottom flap edge 67.

Integrally connected to the back wall panel 52 at vertical fold/scoreline 42 is a second side wall panel 68 which is defined by spaced apartvertical fold/score lines 42, 43 and spaced apart horizontal fold/scorelines 48, 49. Integrally connected to the second side wall panel 68 atfold/score line 48 is second side wall panel top flap 69 having aninverted “U” shaped second side wall panel top flap edge 70. Integrallyconnected to the second side wall panel 68 at fold/score line 49 issecond side wall panel bottom flap 71 having a “V” shaped second sidewall panel bottom flap edge 72.

Integrally connected to the second side wall panel 68 at verticalfold/score line 43 is a front panel 73 which is defined by spaced apartvertical fold/score lines 43, 44, horizontal fold/score line 49 andspaced apart front panel top edge 74. Integrally connected to the frontpanel at fold/score line 49 is second bottom panel 75 which is definedby fold/score line 49, second bottom panel bottom edge 76, first frontbottom panel side edge 77, and second front bottom panel side edge 78.In addition, integrally connected to front wall panel 73 at fold/scoreline 44 is a side connecting flap 79 defined by fold/score line 44,spaced second carton side edge 51, top side flap edge 80 and spacedapart bottom side flap slant edge 81.

To assemble the box blank 40 into a box as shown in FIG. 5, the verticalfold/score lines permit folding of the first side wall panel 63, theback wall panel 62, the second side wall panel 68, the front wall panel73 and side flap 79 to construct a tube of rectangular cross-sectionwith the side flap 70 disposed interiorly and sealed proximate to firstbox side edge 50 from an area proximate to horizontal fold/score line 48to an area proximate horizontal fold/score line 49 e.g. by applicationof an adhesive (preferably one that sets with a high degree oftransparency). The first bottom panel 69 and second bottom panel 75 aredesigned to cooperate to form an interlocking bottom which is adapted tosupport contents within the assembled box (See FIG. 5). First bottompanel 69 is equipped with a connecting tab 82 which is sealed, e.g. byadhesive, to first side wall panel bottom flap and second bottom panel76 is similarly equipped with a connecting tab 83 which is similarlysealed, e.g. by adhesive, but to second side wall panel bottom flap 71and by provision of these seals and the sealing of the side connectingflap as previously disclosed, the carton box may be stored in a flatcondition ready for assembling into a free standing self-supportingrigid box as seen in FIG. 5. When the flattened box bottom is alongfold/score line 49 is forced (either manually or by packaging machinery)into a rectangular configuration, the first and second bottom panelssnap together to form a rigid base which maintains the boxconfiguration.

Referring now to FIG. 5, a perspective view illustrating, the box blank40 of FIG. 4 configured into a parallelepiped box 84 in accordance withthe present invention is shown. Box 84 has a flat base 85 with acontinuous upstanding rigid wall with front wall panel 73 and first sidewall panel 63 shown with side connecting flap 79 adhesively sealingtogether panels 63 and 73. A bag such as that shown in FIG. 3 which ispartially filled with a flowable, preferably liquid, product is leadedinto box 84 and top panel 53 having an access port such as hole 58, isclosed to hold the bag within the box 84. Prior to closing the toppanel, adhesive is applied around the hole 58 on the top panel as wellas on top fold tab 57 so that the tab 57 may be sealed to an insidesurface of the front wall panel 73 and tab 57 proximate hole 58 may besealed to the bag contained within the box 84.

Referring now to FIG. 6, a top plan view of the container box 84 of FIG.5 in accordance with the present invention is shown. Box 84 has a toppanel 53 with hole 58 for providing an access port to interiorlydisposed bag 34 which is adhesively attached to an interior surface ofthe top panel 53. Top panel 53 has a box top perimeter 86 defined byfold/score lines 47, 48 a, 48 b, and 48 c. Also, locations are indicatedfor the front wall panel 73, and rear wall panel 52, connected by spacedapart first and second side wall panels 63 and 68.

Referring now to FIG. 7, a bottom plan view of the container box 84 ofFIG. 5. Locations are indicated for the front wall panel 73, and rearwall panel 52, connected by spaced apart first and second side wallpanels 63, and 68. A flat bottom base 85 has a boundary that is definedby base perimeter 87 formed by score/fold lines 49 a, 49 b, 49 c, and 49d. The first bottom panel 59 having connecting tab 82 interlocks withthe second bottom panel 75 having connecting tab 83 to form the flatbottom base 85 in the assembled box 84.

It will be appreciated that a variety of folding patterns, boxdimensions and access port locations may be employed in the presentinvention and the folding pattern, box dimensions and access portlocation described herein are exemplary only.

Referring now to FIG. 8, there illustrated an assembled bag-in-boxpackage 100 showing an open box 84 holding a partially filled bag 26.The bag 26 is sealed to an interior surface of top wall 53 adjacent toan access port 58 which may be a hole or other opening. Once closed andsealed shut, the box may be positioned top side down to permit gravityto hold the bag 26 against the interior of top 53 adjacent access port58 thereby ensuring a good adhesive contact between bag film and boxuntil the adhesive sets.

Advantageously, in some preferred embodiments, bag 26 may be formed froma flexible plastic web which is partially or completely transparent. Inother preferred embodiments, box 84 may include one or more “windows”where the paperboard is removed. In these preferred embodiments, whenbag 26 is partially or completely transparent and box 84 is transparentor includes a window, advantageously the consumer may view the flowableproduct within the package.

Turning now to FIG. 9, there is illustrated a side view of thebag-in-box package of FIG. 8. Bag 26 is only partially filled with aproduct 38 such as a liquid juice beverage to create an un-filledcollapsed head-space 39 above the product. As previously mentioned, theproduct occupies at most about 87%, 83%, 75%, 67% or 58% of theavailable volume of the bag. The remaining volume of the bag, i.e.,head-space 39 should be void of product and any additional injected gasto allow this portion of the bag to collapse upon itself. Bag 26 issealed to an interior surface of top wall 53 adjacent to an access port58 which may be a hole or other opening.

As previously mentioned, when bag is completely filled with product orwhen there is a gas-filled head-space above the product in a less than acompletely filled bag, the pressure inside the bag causes liquid productto rapidly exit through the straw and spill out onto the consumer.Therefore with the present invention, it is important to not only limitthe amount of product within a particular volume of bag, but alsoprovide a collapsed head-space above the product. To this end, a testwas performed on bags to find the ideal amount of volume of productwithin a bag to minimize or eliminate product from spilling out of astraw when the straw is inserted into the bag. Bags similar to thatdescribed in FIG. 3 and having a length of 18.4 cm (7.25 in) and a widthof 10.2 cm (4 in) were formed from a transparent thermoplastic websimilar to web 10 (TABLE 1) described above. Each bag had an availabletotal volume of approximately 354.9 mL (12 fluid ounce). Bags were thenfilled with various amounts of water and inserted a parallelepiped boxsimilar to that described in FIG. 8, and adhesively secured at a holeconfiguration in the top panel of the box. If the amount of water addedto the bag was less than the total available volume of the bag, thehead-space above the water was collapsed and unfilled. A straw having asharp pointed end was used to puncture through the box and bag. Thistest determined if water exited from the straw when the bag waspunctured as it is being hand-held. The percent of failures are shown inTABLE 2 below.

TABLE 2 Amount of Water (mL) % of Available Volume Added to Bag FilledWith Water Percent of Failures 354.9 100 100% 325.3 92 67% 310.5 87 25%295.7 83 0% 266.2 75 0% 236.6 67 0% 207 58 0% 177.4 50 0% 147.9 42 0%118.3 33 0%

As is evident from the above data, the best performing bags are thosefilled to 87% or less of its available volume which creates a head-spaceabove the water which is collapsed and void of water.

The above description and examples illustrate certain embodiments of thepresent invention and are not to be interpreted as limiting. Selectionof particular embodiments, combinations thereof, modifications, andadaptations of the various embodiments, conditions and parametersnormally encountered in the art will be apparent to those skilled in theart and are deemed to be within the spirit and scope of the presentinvention.

What is claimed is:
 1. A retail bag-in-box package comprising: aflowable product, a bag, and a box; said product contained in said bagwhich is contained in said box; wherein (a) said box has (i) a bottompanel, an opposing top panel, and a self-supporting upstanding wallconnecting said bottom and top panels, (ii) an access port through saidbox; (b) said bag is made from a flexible thermoplastic film,hermetically sealed to itself, and attached to an interior surface ofsaid box proximate said access port; (c) said product occupies at most87% of the available volume of said bag to create a head-space abovesaid product comprising the remaining available volume of said bag; and(d) said head-space is collapsed and void of said product.
 2. A retailbag-in-box package, as defined in claim 1, wherein said product occupiesbetween 50% and 83% of the available volume of said bag.
 3. A retailbag-in-box package according to claim 1, wherein said bag has a WVTR ofless than 0.5 g/100 in²/24 hours at 100° F. (38° C.), 90% Relativehumidity (R.H.), and 1 atmosphere.
 4. A retail bag-in-box packageaccording to claim 1, wherein said bag has a WVTR of less than 0.1 g/100inches² per 24 hours at 100° F. (38° C.), 90% Relative humidity (R.H.),and 1 atmosphere.
 5. A retail bag-in-box package according to claim 1,wherein said bag has a puncture resistance of between 4.4 N (1 lb-force)and 22.2 N (5 lb-force).
 6. A retail bag-in-box package according toclaim 1, wherein said bag has a total internal capacity of less than orequal to 1000 mL (33.8 oz).
 7. A retail bag-in-box package according toclaim 1, wherein said bag has a total internal capacity of between 118mL (4 oz) and 946 mL (32 oz).
 8. A retail bag-in-box package accordingto claim 1, wherein said bag has a total internal capacity of about354.9 mL (12 oz).
 9. A retail bag-in-box package according to claim 1,wherein said bag comprises at least five layers including a heatsealable layer, and a layer of EVOH.
 10. A retail bag-in-box packageaccording to claim 1, wherein said bag has an O₂TR value of less than orequal to 10 cm³/100 in²/24 hours at 1 atmosphere, 23° C. and 0% RH. 11.A retail bag-in-box package according to claim 1, wherein said bag hasan Elmendorf tear strength value of at least 100 grams in at least oneof the machine and transverse directions.
 12. A retail bag-in-boxpackage according to claim 1, wherein said bag film has a Gurleystiffness of less than 50 grams.
 13. A retail bag-in-box packageaccording to claim 1, wherein said product comprises a liquid.
 14. Aretail bag-in-box package according to claim 1, wherein said boxcomprises paperboard.
 15. A retail bag-in-box package according to claim1, wherein said box comprises amorphous polyethylene terephthalate(APET).
 16. A retail bag-in-box package according to claim 1, whereinsaid box wall has a Gurley stiffness of at least 1000 grams.
 17. Aretail bag-in-box package according to claim 1, wherein said packagefurther comprises a rigid straw, a pump, a tap, a valve, a sprayer, atwist screw cap, or a dispensing cap.
 18. A retail bag-in-box packageaccording to claim 1, wherein said bag is transparent.
 19. A retailbag-in-box package according to claim 1, wherein both said bag and saidbox are each transparent.
 20. A retail bag-in-box package according toclaim 1, wherein said bag is transparent and said box is formed frompaper board and has at least one window.